Advanced process design for re-contouring using a time-domain dynamic material removal simulation

Denkena, Berend; Pape, Oliver; Grove, Thilo; Mücke, A.

doi:10.1016/j.procir.2019.02.005

Cited by 4 publications

(4 citation statements)

References 12 publications

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“…For a given set of process parameter values, the NC program is subdivided into discrete time steps, which correspond to engagement situations along the given tool path. Instead of directly using the TCP to position a tool model, an interpolation along the trajectory of the cutting edge is applied [11,25]. This is necessary due to the superposition of TCP and tool rotation.…”

Section: Extension Of a Geometric Physically-based Simulation Systemmentioning

confidence: 99%

“…While the calculation of process forces using empirical models in combination with undeformed chip thicknesses has been widely used [9,11,20], the determination of force directions based on topographic information is a novel approach. By using a structured grid discretization, the force directions can be calculated for each cutting segment separately with respect to topographic features of the considered tool.…”

Section: Calculation Of Process Forcesmentioning

confidence: 99%

“…An essential process characteristic is the resulting chip thickness during machining, which can be used to predict process forces. Especially for the analysis of process stability and tool wear, a precise prognosis of the occurring chip thicknesses is needed [11][12][13]. The determination of so called undeformed chip thicknesses during cutting operations has been subject to various abstractions to ensure feasibility in regard to simulations of whole processes [14].…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Modeling of cutting forces in trochoidal milling with respect to wear-dependent topographic changes

Bergmann

Potthoff

Rickhoff

et al. 2021

Prod. Eng. Res. Devel.

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The aerospace industry utilizes nickel-based super-alloys due to its high level of strength and corrosion resistance. To evaluate milling strategies regarding tool wear, the prediction of forces during these cutting operations is essential. This comprises the determination of the undeformed chip thickness. Due to the complex interdependencies of tool engagements, the determination of these thicknesses is challenging. A geometric physically-based simulation system was extended by a novel time-discrete envelope model to increase the precision of the calculated undeformed chip thicknesses. In order to take tool wear into account, digitized topographies of cutting inserts in different states of tool wear were modelled.

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Section: Extension Of a Geometric Physically-based Simulation Systemmentioning

confidence: 99%

Section: Calculation Of Process Forcesmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Modeling of cutting forces in trochoidal milling with respect to wear-dependent topographic changes

Bergmann

Potthoff

Rickhoff

et al. 2021

Prod. Eng. Res. Devel.

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show abstract

“…an adapted process damping model, have to be realized, to increase the accuracy of the simulation. Another potential way of calculating stability charts is the use of time-domain milling simulations [16,17].…”

Section: Discussionmentioning

confidence: 99%

Using tool wear to increase process stability when milling Al7075 and AISI 4140+QT

Denkena¹,

Krödel²,

Relard³

2021

Prod. Eng. Res. Devel.

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One of the main limits of productivity during cutting processes is the occurrence of regenerative chatter. Due to these self-excited vibrations, the load capacity of the machine components, the tool as well as the machine performance cannot be fully utilized. There are several methods to stabilize the milling process. One is the use of increased process damping, which results from the contact of the tool’s flank face and the workpiece. The flank wear land naturally increases the contact between tool and workpiece. However, this effect has not been used to increase productivity in milling processes. This paper investigates with experiments and numerical simulations how tool wear affects process stability in milling of aluminum and steel. Therefore slot milling and side milling tests were carried out with tools of various states of flank wear. It could be shown that increasing flank wear allows to raise the depth of cut ap up to 300% in machining aluminum and perform the machining process with a higher productivity.

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Simulation-based design of flank face modification for the milling of Ti-6Al-4V and Inconel 718

Denkena

Bergmann

Worpenberg

2022

Int J Adv Manuf Technol

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The milling of titanium and nickel-based alloys leads to high tool wear due to the high thermomechanical load on the tool. By modifying the flank face on end mills, it is possible to limit the increase in the width of flank wear land, thus increasing tool life, component quality and increasing the allowable productivity of the tools. The flank face modification is characterized by the width and depth of the undercut and the rounding in the undercut of the modification. Through a simulation-based approach, a method is created to design the flank face modification in a load-optimized way and thus to use the full potential in the respective application cases.

show abstract

Advanced process design for re-contouring using a time-domain dynamic material removal simulation

Cited by 4 publications

References 12 publications

Modeling of cutting forces in trochoidal milling with respect to wear-dependent topographic changes

Modeling of cutting forces in trochoidal milling with respect to wear-dependent topographic changes

Using tool wear to increase process stability when milling Al7075 and AISI 4140+QT

Simulation-based design of flank face modification for the milling of Ti-6Al-4V and Inconel 718

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